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lucas epic diesel injection pump

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lucas epic diesel injection pump

Postby crane driver » Sat May 26, 2012 6:07 am

My transit has a 2.5.turbo diesel 5 spd manual and is from 2000.
I had some trouble with the lucas epic injector pump which was leaking fuel and have taken it out to have the seal replaced and thanks to the good people here who supplied with the best information needed It was a job I now have been able to master.

The pump went back in and started up with no problem ,and with a new timing belt.
However the guy that replaced the seal on the pump told me that my lucas epic injector pump really needs rebuilding and at a cost of $1800 isnt cheap for me thats 1120 converted into pounds.
He showed me the bearings have some play in them and basically it will only be a matter of time before that play in the bearings will ruin the new seal and then start leaking fuel all over again.

I havent got a lot of money to spend at the moment so it was just the seal that day and then refitted it back on to the engine.
Which started up fine but did/could not ref over 3000 rpm on the test drive.
This significant loss of engine power caused me to ring the guy that replaced the seal and I have been informed this is due to the metal dust from the worn out parts inside is now clogging up the pump which is taken back out again.
The pump has been held horizontal to upside down and the metal dust inside it must have moved and clogged the system up.
Ironically the pump looked pretty new when I bought the van almost one year ago.

How hard is it to strip down the pump to do a rebuild myself?
Are rebuild kits available?
Are there any other types of pump that can be fitted instead ,like a manual pump?

I will be in Europe in a couple of weeks time for a short stay with friends and familie,
I can definitely look around for another pump while I am there.

All good advice is welcome.
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Re: lucas epic diesel injection pump

Postby MinorMatt » Sat May 26, 2012 9:15 am

its a manual so you can fit a bosch mechanical pump from a non turbo.

You have to tweak the fuelling and advance the timing but it all works well

Look for one from 1997 onwards :)
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Re: lucas epic diesel injection pump

Postby psv-hgv-flt » Sat May 26, 2012 10:21 am

crane driver wrote:My transit has a 2.5.turbo diesel 5 spd manual and is from 2000.
I had some trouble with the lucas epic injector pump which was leaking fuel and have taken it out to have the seal replaced and thanks to the good people here who supplied with the best information needed It was a job I now have been able to master.

The pump went back in and started up with no problem ,and with a new timing belt.
However the guy that replaced the seal on the pump told me that my lucas epic injector pump really needs rebuilding and at a cost of $1800 isnt cheap for me thats 1120 converted into pounds.
He showed me the bearings have some play in them and basically it will only be a matter of time before that play in the bearings will ruin the new seal and then start leaking fuel all over again.

I havent got a lot of money to spend at the moment so it was just the seal that day and then refitted it back on to the engine.
Which started up fine but did/could not ref over 3000 rpm on the test drive.
This significant loss of engine power caused me to ring the guy that replaced the seal and I have been informed this is due to the metal dust from the worn out parts inside is now clogging up the pump which is taken back out again.
The pump has been held horizontal to upside down and the metal dust inside it must have moved and clogged the system up.
Ironically the pump looked pretty new when I bought the van almost one year ago.

How hard is it to strip down the pump to do a rebuild myself?
Are rebuild kits available?
Are there any other types of pump that can be fitted instead ,like a manual pump?

I will be in Europe in a couple of weeks time for a short stay with friends and familie,
I can definitely look around for another pump while I am there.

All good advice is welcome.


look hear.

viewtopic.php?f=31&t=59343&p=516381&hilit=epic+training+manual#p516381

viewtopic.php?f=4&t=66106&hilit=epic+to+bosch+686

:wink: :wink:
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Re: lucas epic diesel injection pump

Postby crane driver » Sun May 27, 2012 9:56 am

Thanks for all the valuable information supplied
I will start looking for a bosch 686 pump.
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Re: lucas epic diesel injection pump

Postby MinorMatt » Sun May 27, 2012 10:49 am

Any post 1997 bosch pump will do ;)

145/146 are the best though (686-2 and 686-3 in big numbers)
Transit 120 Turbo'd DI Manual. 1/4 in a smooth and leisurely 18.82s. Now where's these faster Automatic Di s?
Transit 150 TDi (100PS EPIC) Hi-Top

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Re: lucas epic diesel injection pump

Postby Altransit » Sun May 27, 2012 5:07 pm

Before you go to all the trouble, are you sure it was timed up correctly, and was a new belt and tensioner fitted at the same time :?:
1997 Mk5 SWB 115 Minibus 70ps Di
2004 Mk6 SWB T280 Medium Roof 85PS TDDi - Vantunered
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Re: lucas epic diesel injection pump

Postby crane driver » Sun May 27, 2012 7:15 pm

MinorMatt wrote:Any post 1997 bosch pump will do ;)

145/146 are the best though (686-2 and 686-3 in big numbers)

OK thanks ,that will be handy to know that any post 1997 bosch ( 4 cylinder ) pump will fit.
Thanks. :>)
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Re: lucas epic diesel injection pump

Postby MinorMatt » Sun May 27, 2012 7:18 pm

I meant any post '97 TRANSIT bosch pump will do, just to clear things up
Transit 120 Turbo'd DI Manual. 1/4 in a smooth and leisurely 18.82s. Now where's these faster Automatic Di s?
Transit 150 TDi (100PS EPIC) Hi-Top

Gaffa tape is like "the force" - it has a light side, a dark side, and it holds the universe together.
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Re: lucas epic diesel injection pump

Postby crane driver » Wed May 30, 2012 3:06 am

MinorMatt wrote:I meant any post '97 TRANSIT bosch pump will do, just to clear things up

Thanks for that and I haven not yet found a bosch pump yet but have come across another lucas ,for the moment I will fit that one back in and keep an eye out for a bosch.
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Re: lucas epic diesel injection pump

Postby crane driver » Wed May 30, 2012 3:24 am

Altransit wrote:Before you go to all the trouble, are you sure it was timed up correctly, and was a new belt and tensioner fitted at the same time :?:

Yes I fitted a new belt when i refitted the pump , started up up fine and went for a drive and noticed a significant loss of power as in nothing over 3000 rpm I did try and reset the timing a little at the wheel but it made no difference in regards to engine power.

The pump itself has been upside down and side ways in a workshop bench while the diesel specialist changed the seal over ,he also explained that the worn out bearings and the other worn out moving parts is the main cause of my pump malfunction and created by the metal dust that is still trapped inside the pump.
The magnet was full but there was much more.
I think that while handling and transporting the pump the metal dust inside it has resettled and is now clogging the pump in ways that it was not before.
I took the pump back out and have found another lucas at a reasonble price that I will go and pick up this weekend.
For the long term i will definitely keep looking for a Bosch pump ,it is not such a bad idea to carry a spare around and now that I know how easy it is to change one over I only need to carry a minimum of tools should such an event arise.
I have ordered the belt tensioner by the way thank you.
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Re: lucas epic diesel injection pump

Postby Kestrel » Sat Dec 15, 2012 12:15 pm

Hi,
Have a diesel leak, dripping at a rate of maybe 30 drops per min causing me to get really bad mpg obviously. The leak is not from the solenoid as it would be impossible for the leaking diesel to reach the drip point from the solenoid position (unless diesel doesn't obey the laws of gravity). The pump is a Lucas epic and is dripping from the bottom, beneath the hex bolted plate (but not from the plate itself). Top of pump is completely dry and can't see any wetness down the engine side of the pump. Guessing from the posts and info. that this would be a guilty square 'o' ring issue?
Is this serviceable or am I looking at an expensive trip to diesel pump repair/replacement guys?
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Re: lucas epic diesel injection pump

Postby AndyG » Sat Dec 15, 2012 11:29 pm

Image
Ford Transit 120 TDI EPIC Automatic. 0-60 in a leisurely and smooth 12.7 seconds and 1/4 mile in 19.1 seconds. Now where's all these faster? manual Di s?
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Re: lucas epic diesel injection pump

Postby Kestrel » Sat Jan 12, 2013 5:26 pm

Fixed with ease, thank you for link :)
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Re: lucas epic diesel injection pump

Postby AndyG » Sat Jan 12, 2013 6:32 pm

Kestrel wrote:Fixed with ease, thank you for link :)
8)
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Ford Transit 120 TDI EPIC Automatic. 0-60 in a leisurely and smooth 12.7 seconds and 1/4 mile in 19.1 seconds. Now where's all these faster? manual Di s?
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Re: lucas epic diesel injection pump

Postby danderv » Wed Jan 16, 2013 11:27 pm

Some will say the epic never fails and its the timing belt but i can safely say i have never seen timing out on removal of a faulty pump. :D
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